DEKRA Industrial. Torbjörn Sjö, Mats Wendel and Jorge Benitez, Business Area Nuclear

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1 DEKRA Industrial Torbjörn Sjö, Mats Wendel and Jorge Benitez, Business Area Nuclear

2 DEKRA in General One of the leading service provision companies in Europe Based in Stuttgart Operates in more than 50 countries Divided into 3 Business Units and 15 Service Lines Generates more than 1.7 billion Euros in sales Employs around 25,000 employees 2

3 Tecnatom Group Joint Capabilities for VVER and RBMK Market 3 Tecnatom S.A is an engineering Spanish company owned by the Spanish main electrical utilities Tecnatom employs around 750 persons Tecnatom is a global leader company in delivering advanced engineering solutions that has been providing services to the nuclear industry since its creation in 1957 The company s main activities centres on the rendering of inspection and component structural integrity services, the training of operations personnel by means of full-scope simulators and engineering in support of plant operation for the power generation market Tecnatom has two subsidiaries in France Metalscan and Multi2000 (M2M) companies for R&D in the area of NDT and a joint venture company in China (CITEC company) with CGNPC (China Guandong Nuclear Power Company) for PSI and ISI services providing CHINA (Beijing) CHINA (Shenzhen) Madrid (Head Quarters) Chatenoy Chalón sur Saône Cataluña (Technical Support Centre) Technical Support Centre at: Cofrentes NPP SMª Garoña NPP Agents: Argentina, Brazil, Bulgaria, Rep. of Korea, China, Mexico, Russia, Taiwan, Ukraine.

4 DEKRA Resources for NDE DEKRA more than 615 persons with NDT certificates Mechanized inspection: More than 80 persons with NDT certificates More than 10 design engineers 4

5 Experience of our staff Development Design of manipulators Vessel, Nozzle, BMI Internals Piping Control systems NDE development UT Sizing TOFDT Phased array ET VT, AVT-replika Probes for special applications Inspections BWR PWR VVER RBMK Conventional industry 5

6 Development of manipulators for PWR The task was to perform a qualified inspection of all vessel welds including nozzles, bottom nozzles and VT of the radial supports in Ringhals 2,3 and 4 Conclusion: a new concept is demanded in order to perform a full vessel exam in 5 days The Customers voice: A scope of this extent has never been performed before 6

7 Inspection order for PWR Ringhals 2-4 Parallel inspection! Inspection of the whole reactor in 5 days Skidbladner: Circumferential and longitudinal shell welds including the bottom dome Särimner: Inlet and Outlet Nozzles, Nozzle to shell welds, inner radius and connection welds Gungner: BMI Nozzle and J-groove Draupner: Moulding VT tool for BMI J-groove weld 7

8 VVER Vessel manipulators for parallel inspection 8

9 Manipulator for Inspection of RPV Welds and base material 9 Manipulator for inspection of VVER 440 Circular rail mounted in the lower support for inspection of the lower part of RPV and the circular rail mounted in the water dividing ring for inspection of the upper region. (Note that the curved rail in the upper position is hidden in these pictures.) Manipulator for inspection of VVER 1000 The figure shows the rail mounted in the two different positions and also the different vertical position of the mast compared with the position in a VVER1000. (Note that the curved rail in the upper position is hidden in these pictures.)

10 Manipulator for Inspection of Ø850/500 mm nozzles 10 Manipulator for inspection of Ø850/500 mm nozzles, showing probe pans for the nozzle bore and inner radius. The figure also shows the ROV thrusters and floatation blocks with slots for centering arms. The cables are attached in the centre of the manipulator and designed to allow a rotation of more than 400 Manipulator for inspection of Ø850/500 mm nozzles, showing an inspection camera in the in the floatation block slot and the probe-pan for inspection Inner Radius and probe pan for inspection of Nozzle bore

11 Manipulator for Inspection ECCS nozzles 11 Manipulator for inspection of ECCS nozzles, showing the inspection camera in the in the floatation block slot and also the camera for inspection the nozzle components welded to the vessel wall. The figure also shows the ROV thrusters and floatation blocks with slots for centering arms. The cables are attached in the centre of the manipulator and designed to allow a rotation of more than 400 Manipulator for inspection of ECCS nozzles, showing the probe-pan for inspection of the connection weld between the ECCS nozzle and the pipe. Note: this is an Option

12 Vessel manipulator Skidbladner Light weight and easy to handle Neutrally buoyant Allows for parallel activities Inspection of circumferential and longitudinal shell welds including the bottom dome Positioning and attachment in known reference points in the vessel Upper region (four positions) Lower region (four positions) 12

13 Vessel manipulator Skidbladner Launching and fixation Manually by two operators, from refueling machine or auxiliary bridge Fixed references The radial support guides give a repeatable and precise position in direct relation to the vessel, with no need for complicated positioning system Facilitates parallel work For other manipulators or Inspection cameras etc. 13

14 Nozzle manipulator Särimner ROV- Scanner manoeuvring between nozzles Manually launched into the water from the auxiliary bridge, with no need of polar crane. The ROV functions and centering is remotely controlled with a wireless joystick Inspection of: Nozzle to shell welds Inner radius Connection welds Nozzle bore 14

15 BMI (Bottom Mounted Instrumentation) Nozzle Manipulator Gungner ROV-Scanner manoeuvring between nozzles (Surveillance by an underwater camera) Inspection of: Inner surface of nozzle Connection weld J- groove from ID J- groove and HAZ from OD of Nozzle 15

16 Moulding VT Tool Draupner A moulding tool based on the BMI Nozzle manipulator concept which will be remotely controlled with rods and a wire system The moulding tool makes a mould from the full circumferential of the BMI J-groove weld Detection target 2mm x 3µm 16

17 Visual Inspection of Radial Support Welds Qualified inspection; Procedure VT01 Inspection with a camera connected to the rigid pole-system Detection target 20µm x 5mm 17

18 Parallel work in Ringhals 3, September 2010 Full vessel inspection in 5 days. Probably a world record! 18

19 Training and qualification 19

20 Inspection of stellite cladding on surface of Core Plate Radial Support key The scanner placed in the mockup 20 The inspection includes both UT and ET: Surface testing using Eddy Current to establish presence of cracks and their positions TOFD testing using multiple probe separations in order to exactly measure crack size over varying depth TOFD testing to verify stellite layer thickness TOFD testing to detect lack of fusion between stellite layer and base material Cracks in the stellite surface

21 The VHP system in inspection configuration and in service mode 21

22 PUTS Mechanized Inspection of stainless steel welds in piping The project has qualified Phased array techniques for all Swedish NPPs Single sided inspection Direct longitudinal response 22 Figure: Merge degrees SLL Shear (S)

23 Steam Generator welds Qualified technique developed for Ringhals Circumferential and longitudinal welds with TOFD technique Nozzles with TOFD and pulse echo 23

24 Mechanized PT OD and ID inspection of steam dryer for Oskarshamn 24

25 Control rod inspection new manipulator: Styrbjörn Starke Inspection speed increased 4 times! New probe head, UT and ET Handles two control rods in parallel Two manipulators used, four control rods in operation 25

26 Probe design ET Star probe for defects in all directions ET and UT BMI Nozzle ID 26 ET and UT VHP

27 Key support and clevis measurement GOAL Measurements of the worn surfaces shall come within an accuracy of ± 0,05 mm depth wise. On the worn surfaces on the clevis key, the wear shall be reciprocally comparable within an accuracy of ± 0,1 mm. As a result; cavities in one surface shall be comparable with elevations in the other, this is required in order to determine and show the total play in the application. 27

28 The DEKRA advantage We are one of the largest organizations for manual and mechanized inspections in Europe! Worldwide operations, important to understand local culture and language. Many employees speak Russian. Independent supplier of all types of inspection Existing solutions for mechanized inspection in Nuclear power plants. State-ofthe-art manipulators developed for PWR and VVER A broad scope of deliveries together with our partner Tecnatom Experienced engineers, projects in PWR, BWR, VVER and RBMK QA and QC resources for new plants/upgrade Several labs for destructive testing 28

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